Method for producing high-grade fertilizer

ABSTRACT

A method for producing a fertilizer and decay promoting substance by subjecting grape marc to aerobic decay so that in a first phase, the sugar content is converted to alcohol and bacterial fermentation produces organic acids. During the first phase, the alcohol and acids react to produce aromatic esters and a decay stabilized mass. In a second phase, the mass is rearranged to facilitate access of air and promote penetration of the mycelia of a thermophilic actinomycete into the mass. In a third step, the mass is rearranged to effect microbial degradation by the actinomycete mycelia and the mass is dried and the pip-containing fraction is separated. The thus obtained pips or seeds are infested with mycelia and still contain their natural oil content and constitute an excellent high-grade fertilizer and aerobic decay promoting agent for the decay of vegetable and animal waste materials.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of copending application Ser.No. 812,856, filed July 5, 1977, and now U.S. Pat. No. 4,211,545, July8, 1980, the contents of which are incorporated herein by reference andis based on disclosure document No. 078047, filed on Feb. 13, 1979, thecontents of which are also incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to the utilization of the degradation of organicmatter to produce usable heat energy and fertilizer.

2. Description of the Prior Art

It is estimated that the amount of energy released annually on earthfrom biomass is thirty times the amount released by all man-mademachines. The biological flow of energy, however, generally proceedsunobtrusively. Organic material, finely divided in the humus layer ofthe soil or in water, is decomposed by organisms with the evolution ofheat back into the starting materials.

The decaying processes which take place, for example, over a large areain the scattered layer of the forest floor, can, however, beconcentrated. It is for this reason that every gardener is advised tocollect plant waste in stacked heaps having a volume of approximatelytwo cubic meters in order to achieve, by such concentration, a highdegree of heat and a vigorous rotting, resulting from the combinedeffects of the many material and energy conversions taking place. Someorganic materials, such as, straw or wood waste, must be heaped in evenlarger amounts and require nitrogen-containing materials to be mixed inin order to initiate a vigorous, hot rotting.

Most natural processes proceed more rapidly at higher temperature levelsthan at lower ones. This is also true for humification. The heat whichdevelops in the center of the compost heap indicates a vigorousmetabolic selectivity of thermophilic micro-organisms. Along with thedegradation and conversion of the organic substances, the hightemperature also has certain positive aspects. Thus, it becomes too hotfor the development of fruit flies and other unwelcome diptera. Variousstages of parasites, plant pathogens and pathogenic micro-organisms areput at a disadvantage in the hot rotting material and are killed as arethe seeds of weeds, if the heating is sufficiently strong and penetratesthe mass.

SUMMARY OF THE INVENTION

I have discovered a method for preparing a substance which can initiate,promote, and sustain the decay of organic materials at highertemperatures. Additionally, the substance prepared by the presentprocess can be used to prepare very high grade fertilizer.

More particularly, the substance of the present invention comprisesgrape pips obtained by the aerobic decay process of the presentinvention and which are thereby infested with humicola and also stillcontain their natural oil content. This substance is prepared by

(a) subjecting a mass of grape marc to aerobic decay wherein

1. the sugar content of the marc is converted to alcohol which reactswith organic acids produced from bacterial fermentation and the acidsand alcohols react to produce esters;

2. rearranging the decaying marc to facilitate access of air thereto topromote penetration of the mycelia of a thermophilic actinomycete intothe mass;

3. rearranging the mass into a loose form to effect microbialdegradation by the actinomycete mycelia; and

(b) drying the mass and separating a pip-containing fraction.

The pips are normally opened up, as by crushing, before use and areparticularly suitable for use as a high grade fertilizer or as anaerobic decay promoting agent to promote the decay of vegetable andanimal waste materials.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Preferably, the growth of thermophilic actinomycete of thestreptosporangium type is promoted during stage (2) after theesterification step. The decay promoting substance of the presentinvention may be employed by arranging the crushed pips in concentratedform within or below the center of a pile of vegetable waste as aninitiation point for the decaying process. Optionally, a portion of thecrushed pips may be distributed in the bulk of the vegetable waste. Thistype of application is suitable for the decay of waste materials whichcontain straw, bark, gardening waste, spent mushroom compost, wood chipsor the like. The application of the decay promoting substance of thepresent invention for the hot decay of human or animal feces as well asof weeds is particularly valuable. The material can also be used for theodor-free decay of waste with a high protein content, for example,mushroom waste, animal cadavers and the like.

If fertilizer is to be produced from the material itself, urea, organicphosphorus and/or nitrogen compounds, animal fertilizer and/or minerals,trace elements, plant ash or vegetable waste, for example, chopped upgrape vines, may be added to the crushed pips before or during thedecaying process. Since the fertilizer in some cases possesses anextremely high effectiveness, it is advisable to leach the crushed pipsat the conclusion of the decaying process. The leached, crushed pips canthen be used as a substrate for humus closets. The leaching solution canthen be used as a high-grade liquid fertilizer.

The production of the grape pips commences with the storage of freshgrape marc between wooden walls, which are lined on the inside withexpanded aluminum. There should be narrow aeration gaps between thewooden posts or boards which form the outer wall. The mats of expandedmetal at the interior sides are to be adjusted so that, in spite ofuniform aeration, a maximum of moisture is condensed by the inclinedmetal surfaces of the expanded aluminum and returned to the warm marcmaterial.

The temperature increases slowly in the mass of the fresh press residuesand the yeasts multiply and ferment the sugar content of the grape marcto produce alcohol and carbon dioxide. At the same time, differentanaerobic, living strains of bacteria carry out fermentation processeswhich produce organic acids. During this phase, especially smallermasses of marc tend to remain at a temperature level of 45° C. Thespecial wall of wood and expanded aluminum metal now comes into play inthat it provides, on the one hand, a certain degree of insulation and,on the other, moderate aeration through the expanded metal mats. Underthese conditions, an aerobic, acid-tolerating and thermophilic strain ofactinomycetes, preferably of the streptosporangium type, develops andgrows with its whitish gray mycelia from the outside into the substrate.In so doing, it assists considerably in driving the temperature above50° C. in all regions of the mass. The acidic reaction taking placemaintains the pH at about 4 to 5 which corresponds to the requirementsof the organisms.

As soon as the range of 50° C. has been exceeded, the alcohol and theorganic acids thus produced begin to react rapidly with one another.Esters are formed which endow the material with a strong brown color anda specific, aromatic odor. In this stage, the organic acids, whichpreviously had an annoying odor, are chemically bound by theesterification. The temperatures in this phase are far above 33° C., sothat a mass increase in pomace flies is prevented.

The first step of the process is concluded with the systematicesterification. The result is a material which can be stored relativelywell and which has a high energy content of about 17,000 kjoules/kg duesolely to the stable ester component.

In phase 2. of the process, which may follow directly or after anintermediate storage period, this material is used as an energy carrierin that the mycelia of the aforementioned thermophilic strain ofactinomycetes are permitted to grow completely through and permeate themass.

Heat exchangers, which give off heat to the outside through a current ofair or a circulating flow of water, may be mounted in the center of themass of esterified marc material. A vessel may also be arranged in thecenter and connected with the waterline. By so doing, the water isheated up to a temperature of about 64° C.

A cubic meter of marc, which is completely permeated by theactinomycetes species, gives off heat for about one month. As anapproximate rule, it may be assumed that two cubic meters remain hot fortwo months and five cubic meters for about five months without theactinomycete-decaying process coming to a premature halt as a result ofthe constant dissipation of heat.

Accordingly, a small room or a stall may be heated for the entire winterwithout having to expend any additional work energy during the period.The preparation of hot water can also be carried out for long periods oftime and, in practice, up to the next grape harvest if, after properstorage, new packages of esterified material can be placed around thewater container. It is, however, most convenient to utilize the heatsoon after the harvest when the cold period of the year commences. Atthat time, the microbial release of the energy of the sun, which hasbeen chemically bound during the warm vegetation period, is particularlydesirable.

If the marc is mixed, i.e., rearranged, at the end of phase 2.,temperatures of 68° C. to 84° C. are attained after two to three days.This post-decay is not desirable for a long-lasting, uniform utilizationof heat, but is particularly important for the humification of the pulpand skin residues, at the end of which, the marc takes on a dark color.Spores of different thermophilic micro-organisms remain on the surfaceof the pips in the dormant state until they become functional again in afurther decaying process.

The material is now dried. At the same time, the residual heat of thepost-decaying process and the waste heat of any continuing main decayingprocess of phase 2 can be utilized.

The grape pips can be separated from the already decayed marc componentsby a sieving process. In so doing, about 40% of the volume is composedof material which can be immediately used as an organic fertilizer. Thegrape pips make up about 60% of the volume and constitute an energycarrier which can be kept for a long period.

Before the pips are used in accordance with the present invention, theyare opened, for example, by crushing. The pips are seeds, at whose outerwalls exist, depending on the prior treatment, thermophilicmicroorganisms in the dormant state, while the inner wall surrounds theembryo and the blastodermic layers. The latter are killed by the heatand are in the initial stages of a slow degradation. The slowdegradation processes are brought to a halt by drying. The content ofthe pips is very rich in energy because of the presence of grape-pipoil, and about 20 kjoule/kg can be expected.

In addition, the pips contain all of the nutrients necessary for thedevelopment of a seedling and therefore, also the substances formicrobial growth. When the individual components of the grape pips areexposed during crushing to the oxygen of the air and a moisture of morethan 23%, vigorous decay processes commence immediately. The crushedpips can be moistened with cold or warm water. The moist, crushed pipscan now be used at the desired location.

By opening the pips, the microbe spores at the surface come togetherwith the oil and food reserves in the interior of the seed residues.Within the course of a few hours, a decaying process sets in which, justlike phase 2., permits a systematic withdrawal of heat, for example, forcontrolling the temperature of a room, or heating water. This decayprocess is especially suitable for controlling the temperature andhumidity of and supplying carbon dioxide to plants cultivated underglass or plastic film. The crushed pips in the receptacles of expandedmetal give off heat and supply the atmosphere of the glasshouse withcarbon dioxide, so that any ventilation for supplying carbon dioxide,which would be associated with heat losses, becomes superfluous.

Crushed pips may be embedded in materials which, on their own accord,cannot cross the energy threshold to a vigorous, hot decaying process,in order to draw these materials into the thermophilic range or toaccelerate their decay. It is also possible to incorporate nests ofcrushed pips in these materials for which a space of 0.02 m³ issufficient and in which high temperatures rapidly build up. The crushedpips may be mixed in uniformly or preferably, a layer of crushed pips isformed in the lower region which then heats the substrate above.

The most important interaction that takes place consists of the exchangeof heat. The next most important interaction may be the output of sporesof thermophilic micro-organisms which develop in the vicinity of thepips and are carried upwards by the moist current of air. The decayingmaterial may also, however, be surrounded on all sides by crushed pips.This latter procedure is recommended in the case of protein-richsubstances, waste meat, mushrooms or unpleasantly smelling feces. Wastemeat and animal cadavers may, for example, be placed in a plastic bag ona dry support and covered with crushed pips. Crushed pips are, however,also suitable as a filter layer for urine and as an odor-binding basefor areas in which highly malodorous animal feces and urine areconcentrated. The use of crushed pips effectively prevents annoyingodors from developing.

As a result of the giving off of heat and spores, the crushed pipsfrequently are in a position to force the surrounding substances todecay so rapidly, that their effect can almost be described in terms ofcatalytic capabilities.

If the mixture is packed relatively tightly, a thermophilic fungus ofthe humicola type is likely to be the main form of organism. If thematerial is packed less tightly, actinomycetes have greaterpossibilities for development. Innumerable variations of such methodscan be used. All of them can be employed for an effective recycling.

An example of such recycling is the annual pruning of vines which takesplace in the early spring in vineyards. The vines contain significantamounts of nutrients and trace elements. However, they do not decayreadily and are usually burned at the edge of the vineyards. The ash isthen blown away aimlessly by the wind.

In accordance with the present invention, the ash from the burning ofvines is covered with an approximately equal amount of moist crushedpips. The mass is then mixed and allowed to decay in a well ventilatedreceptacle. By so doing, a portion of the mineral components of the vineash is bound organically and a portion is retained by the huminmolecules. In addition, the mycelia of the micro-organisms form aconnecting structure. The ash component is tied into the crushed pipsand can no longer be blown away when it is returned to the vineyard. Thevines may also be chopped up and added in this form to the freshlyground pips in order to be decayed.

Poultry manure has an unpleasant odor. When added to crushed pips (up to40% of the weight of the pips) and allowed to decay, it loses itsunpleasant properties and, at the same time, increases the phosphoruscontent of the decayed material, since the phosphorus content of thepips is about 0.7% of the dry material. At the same time, ectoparasites,worm eggs, coccidia spores, and the like, which may be harbored in thepoultry manure, are killed.

During this active phase, widely differing components may react witheach other and form special manure or produce special trace elementenriched substrates. Admixtures with a high percentage of soil, loam,clay or ground basalt (about 10% based on the pips) provide significanttemperatures and a substrate which is completely permeated by themycelia of the thermophilic micro-organisms. The decaying process can bedelayed by this addition and the diffusion of gas within the massproceeds more uniformly because the maximum temperatures are also not ashigh. With ground basalt, plant nutrients are supplied which promote theformation of a clay-humus complex which influences the properties ofagriculturally used soils in an advantageous manner. The addition ofpotash is required only infrequently because the crushed pips containabout 3% of potash in the dry state.

Smaller amounts of the substance, which become particularly hot as aresult of the process can, because of their large surface area, losetheir existing moisture content as well as the moisture formed duringthe aerobic decaying process. For this reason, wall elements which leadto the recycling of the moisture are important. The covering also playsa role.

The simplest and most appropriate solution is to cut a plastic coveringfilm in such a manner that it is a little larger than the top opening ofthe receptacle. The covering is spread out on top of this and weighteddown with a correspondingly smaller metal ring, so that a hat is formedin the center into which the moist, warm updraft from the hot decayingcenter rises and gives up condensed water at the cooler interior side ofthe film. The condensed water flows away laterally and, at that locationin the plastic film which contacts the metal ring, a sort of dripstoneforms in the film and the condensed water flows back into a region nearthe center of the material rather than in the direct region of the edge.The return of the moisture to the center region is important since thisis where the more significant losses of moisture occur as a result ofthe chimney action in the spaces between the material in the somewhatlower lying areas.

The surface of the exposed heaps is significantly cooler than theinterior. The probability that all the weed seeds and undesirable sporesfrom this area enter the hotter zone at least once, depends on thenumber of times that the heap is turned over.

However, it is possible to form a hot element from the crushed pips in astationary silo which comes into contact with all parts of the mass atleast once. For this purpose, wall elements of expanded metal mats areused which can be suspended next to one another by any convenient means.A double ring is formed by adding an additional wall element to theouter ring. The space between the two walls is filled with moist,crushed pips and, on the floor within the inner ring, a 5 to 10 cm highlayer of the same crushed pips is deposited, from which a similarheating effect emanates as from the double wall which is filled withcrushed pips.

Since the heat rises and moreover is liberated by the condensation ofwater vapor within the plastic film, all of the material is heatedcompletely, if careful attention is paid to obtaining complete filmcoverage within the inner ring.

In the case of an arrangement with a double wall, depending on thespecific case, larger quantities of crushed pips are normally required.For the average garden owner, the easily assembled ring suffices,depending on the amount of waste. The expanded metal must be adjustedcorrectly only for the recovery of water. The wall of the silo then actsas more than an air permeable wall serving mainly for confining themass.

In order to make thermophilic decay available for smaller quantities ofgardening waste, one need only provide a nest of moist crushed pips inthe center, if possible somewhat below the middle of the mass. Thus, aspecial feature of the present invention is that no other organicmaterial is known which allows such long-lasting thermophilic conditionsto be created using such small quantities and which exerts such anintensive effect on the bonding of other organic and inorganic materialswithout being detrimental to the acceleration of the degradation,conversion and synthesis processes in the composting mass. Thecomponents of the equipment, on the other hand, are of subordinateimportance.

Compared to corresponding processes in the normal compost heap, thepresent method has the advantage that a predetermined mixture can beobtained from different components, which are linked microbially to oneanother under controlled conditions even in the smallest region.

A further area of application for the invention is the raising of buttonmushrooms. The button mushroom prefers a low temperature. Commercially,this mushroom is therefore raised in cellars or in rooms havingcontrolled air conditioning. When the button mushroom compost is removedafter several harvests, the substrate is completely interlaced withfungal mycelia. These fungal mycelia are rather vigorous, even if theyare frequently torn as the compost is turned and worked. In any case,however, the mycelia do not die rapidly, and especially not at theexternal temperatures during the winter or during transition periodsbetween seasons.

A mushroom compost for horticulture or agricultural purposes should bewell decayed. This is especially true for the mycelia themselves, inwhich a significant portion of the nitrogen present is chemically boundin the protein. The degradation of the mycelia can, however, beinitiated rapidly by filling ventilated receptacles of at least 50 litercapacity with crushed pips and incorporating them in a central positionat intervals in the heaps of spent mushroom compost. The crushed pipsrapidly convert to a hot decay stage and, at the walls of the receptaclewhich acts as a heat exchanger, ensure that the adjacent spent compostrapidly reaches temperatures in excess of 30° C. Before the inoculation,the substrate itself has already undergone a hot decay, during which allof the easily degradable components of the compost have already beentaken up by the thermophilic micro-organisms.

When the temperature is increased once again, it is the mushroommycelia, with their preference temperatures of below 15° C., which areaffected most sensitively. At the same time, the heat-emitting marcreceptacle gives off spores of thermophilic actinomycetes through theopenings to the adjacent substrate. These spores immediately commence toprocess the mycelial substance. In so doing, additional heat is producedwhich migrates outwards and, as it proceeds towards the periphery,causes the collapse of the heat-sensitive mycelia.

After this brief initial phase, which represents a significant saving oftime for the maturing of the compost, the process may adjust itself toany convenient long-term temperature which, in any case, leads to moreadvantageous properties of the material.

According to investigations, metabolic products are eliminated by themycelia of mushrooms, which have an inhibiting effect on the germinationand growth of young plants. These inhibiting metabolic productsdisappear during the post-composting.

It is, however, a basic prerequisite for the rapid sequence of theseevents that the living mycelial tissue is killed quickly and ascompletely as possible by the thermophilic micro-organisms together withthe high temperatures of the surroundings. If not carried out alongthermophilic lines, the process takes several times as long. Thedegradation of the mycelia, which are embedded in the substrate,proceeds unobtrusively and slowly.

The situation is different with mushroom waste obtained duringharvesting and to which, at most, small amounts of covering soil adhere.In this case, microbial degradation of protein sets in after some timeand is accompanied by extremely unpleasant odors. In such a situation,it is recommended to scatter in crushed pips which are uniquely able tolead the surrounding substrate rapidly to a hot decay and, at the sametime, ensure that the unpleasant decaying odors are contained. Theaforementioned materials may be added before or during the decay of thecrushed pips.

Accordingly, the germination ability of seed-carrying weeds can beeliminated completely by hot decay of the weeds together with crushedpips. Worm eggs and pathogenic spores in human feces can be reliablykilled if the feces is hot decayed together with crushed pips. If thematerial has reached a temperature in excess of 60° C., it may also beused later for growing vegetables. This also applies to animal feces forwhich it is desirable to kill parasites or their eggs.

When the crushed pips cool down, they are ready for use as a fertilizer.However, even in this stage of slight microbial activity, the crushedpips still possess significant odor-binding capabilities. This isparticularly evident when feces are mixed with the crushed pips, whichimmediately direct the degradation in a low-odor aerobic direction. Forthis purpose, it is necessary to weaken the high-grade fertilizer byleaching, since it has sufficient odor-bonding power even in this stateand since the liquor can be used as a valuable, liquid fertilizer.

What is claimed is:
 1. A method for producing a fertilizer and decaypromoting material comprising:(a) subjecting a mass of grape marc toaerobic decay wherein:1. the sugar content of the marc is converted toalcohol which reacts with organic acids produced from bacterialfermentation and the acids and alcohols react to produce esters; 2.rearranging the decaying marc to facilitate access of air thereto topromote penetration of the mycelia of a thermophilic actinomycete intothe mass;
 3. rearranging the mass into a loose form to effect microbialdegradation by the actinomycete mycelia; and (b) drying the mass andseparating a pip-containing fraction.
 2. The method of claim 1 whereinthe thermophilic actinomycete is of the streptosporangium type.
 3. Themethod of claim 1 wherein the pip-containing fraction is subjected totreatment to open up the pips.
 4. The method of claim 3 wherein thepip-containing fraction is subjected to crushing.
 5. The fertilizer anddecay promoting material prepared by the process of claim
 3. 6. Themethod of claim 1 wherein the temperature during step (a) 1 is aboveabout 33° C.
 7. The method of claim 1 wherein the temperature duringstep (a) 1 is about 45° C. to 50° C. and the pH is about 4 to
 5. 8. Themethod of claim 1 wherein the temperature at the end of step (a) 2 isabout 68° C. to 84° C.
 9. The fertilizer and decay promoting materialprepared by the process of claim
 1. 10. A method for producing afertilizer and decay promoting material comprising:(a) subjecting a massof grape marc to aerobic decay wherein:1. the sugar content of the marcis converted to alcohol which reacts with organic acids produced frombacterial fermentation and the acids and alcohols react to produceesters;
 2. rearranging the decaying marc to facilitate access of airthereto to promote penetration of the mycelia of a thermophilicactinomycete into the mass;3. rearranging the mass into a loose form toeffect microbial degradation by the actinomycete mycelia; and (b)subjecting the mass to a treatment to open up the pips therein.
 11. Thefertilizer and decay promoting material prepared by the process of claim10.